Foldable reusable shipping container

ABSTRACT

An embodiment of the subject shipping container comprises a plurality of side panels, a pair of end panels, and a plurality of releasable fasteners securing the end panels  12  to the side panels  11 . A hook and loop fastener such as Velcro™ is used to secure the end panels  12  to the side panels.

PRIOR HISTORY

[0001] This application claims priority from U.S. ProvisionalApplication 60/237,804, filed on Oct. 4, 2000, the contents of which arehereby incorporated by reference in its entirety.

TECHNICAL FIELD

[0002] The invention relates to a container for shipping freight orother materials, and a method of manufacture thereof. More specifically,the invention relates to a shipping container specifically designed tobe reused multiple times and a method of manufacture thereof.

BACKGROUND

[0003] Corrugated cardboard boxes for shipping freight and other similarmaterials are well known. Lightweight and relatively rigid, these boxesare well suited for shipping freight. However, they are particularlysusceptible to ruptures along its top and bottom. Unlike its sides,which are comprised of solid panels of cardboard, the top and bottom ofthese cardboard boxes are typically comprised of overlapped flaps ofcardboard which are secured together by tape.

[0004] Common cardboard box design often rely on the tape/flap union tosupport most of the load bearing. The bottom of a cardboard boxtypically supports the weight of the freight therein, so it is criticalthat the bottom be strong enough to support the weight of the freight.The top is also particularly susceptible because boxes are often stackedone on top of the other, and often, the top is used to support otherboxes. As such, ruptures can occur when the tape/flap union is incapableof supporting a load.

[0005] Typical cardboard boxes are also not particularly suited forrepeated use, tending to lose their strength and rigidity quite quickly.Handling and exposure to moisture quickly degrades most cardboard boxesand so these containers are typically used only a few times and then isdiscarded.

[0006] Also, if the box needs to be sealed and resealed a number oftimes, the use of tape to secure the top and bottom of these boxes isparticularly cumbersome and degrades the strength of the box. Repeatedremoval and addition of tape to the flap tend to remove layers ofcardboard material from the flap area, degrading the flap and weakeningthe tape/flap union of subsequent applications of tape.

[0007] One improvement to the current box design is to have a solidpanel comprise the top, bottom, and sides of a shipping container. Boxesof this design are known in the art. However, in order to ship boxes ofthis design, circular bands are typically needed to secure the tops andbottoms of the box. The necessity of using bands requires additionalexpense for a banding machine and for the bands themselves. Furthermore,the bands make sealing and resealing the box particularly difficult.

[0008] While known designs of shipping containers may work for itsintended purposes, significant improvement can be achieved by providinga shipping container which is more capable of bearing loads and whichdoes not degrade significantly after repeated use. This can be achievedby providing a shipping container having solid panels made of alightweight corrugated plastic material comprising its top, bottom, andsides, and by providing the shipping container with releasable fastenersto secure the top and bottom of the shipping container.

SUMMARY

[0009] Accordingly, it is a general object of the invention to providean improved shipping container which avoids the disadvantages of priorshipping containers, while affording additional structural and operatingadvantages. One feature of the subject invention is the provision of acost effective shipping container which provides additional strengthalong the containers load bearing top and bottom portions. Anotherfeature is the provision of a shipping container which is easily sealedand resealed.

[0010] Certain ones of these and other features of the invention may beattained by providing a shipping container having solid panels made of alightweight corrugated plastic material comprising its top, bottom, andsides, and by providing the shipping container with releasable fastenersto secure the top and bottom of the shipping container to its sides.

[0011] The releasable fasteners can be of the hook and loop variety,such as Velcro™, or it can be a grommet having a C-clip to lock thegrommet in place. The releasable fasteners extend through the side, top,and bottom of the container, providing the fastener additionalrectilinear support

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For the purpose of facilitating an understanding of theinvention, there is illustrated the accompanying drawings, from aninspection of which, when considered in connection with the followingdescription, the invention, its construction and operation, and many ofits advantages should be readily understood and appreciated.

[0013]FIG. 1 is a perspective view of an embodiment of a reusableshipping container in accordance with the subject invention.

[0014]FIG. 2 is a perspective view of the container of FIG. 1 with endpanels partially detached.

[0015]FIG. 3 is an overhead planar view of one embodiment of a containerblank used to construct the container of FIG. 1.

[0016]FIG. 4 is an overhead planar view of another embodiment of acontainer blank used to construct the container of FIG. 1.

[0017]FIG. 5 is an overhead planar view of yet another embodiment of acontainer blank used to construct the container of FIG. 1.

[0018]FIG. 6 is an enlarged, cross-sectional view of an embodiment of anupper fastener configuration for the container of FIG. 1.

[0019]FIG. 7 is an enlarged, cross-sectional view of an embodiment of alower fastener configuration for the container of FIG. 1.

[0020]FIG. 8 is a cross-sectional view of another embodiment of afastener configuration.

DETAILED DESCRIPTION

[0021] The subject invention is a shipping container particularlyadapted to be reused multiple times, and which includes a novel designwhich improves the strength of the shipping container. As shown in FIG.1, an embodiment of the subject shipping container 10 comprising aplurality of side panels 11, a pair of end panels 12, and a plurality ofreusable fasteners 14 securing the end panels 12 to the side panels 11.In this embodiment, a hook and loop fastener such as Velcro™ is used tosecure the end panels 12 to the side panels 11.

[0022] As shown in FIGS. 1 and 2, the side panels 11 define side edges20 and end edges 21. The side panels 11 are interconnected to each otheralong adjacent side edges 20 to define the container's perimeter. Afirst portion of the fastener 22 extends through upper and lowerportions of a number of side panel 11.

[0023] End panels 12 cooperate with the side panels 11 to define aninterior space wherein freight can be contained. In this embodiment, theend panel 12 defines end panel edges 23, and includes flaps 24 whichextend from the end panel edges 23. The end panel edges 23 provide ahinged junction between the end panel and the flap, allowing independentmovement of the flap 24 with respect to the end panel 12. A secondportion of the fastener 25 extend through the flap 24. One flap 24 ofeach end panel 12 is secured to a side panel 11.

[0024] The side panels 1 land end panels 12 can be made of a relativelyrigid, corrugated plastic material such as polypropylene orpolyethylene. In addition to the strength and durability provided by thecorrugated plastic material, the use of such materials allows thesubject shipping container 10 to be ultrasonically welded together,providing even greater strength and stability to the shipping container10. Ultrasonic welds 27 meld portions of the shipping containertogether.

[0025] As shown in FIG. 3, in one embodiment, the subject invention isformed from a one-piece blank. The side panels 11 are hingedlyinterconnected to each other along adjacent side edges 20. A first sidepanel 30 defines opposite end edges 21, from which, the end panels 12extend. A side panel flap 31 extends from a side edge 20 of a secondside panel 32. The container 10 is erected by positioning the side panelflap31 adjacent to the first side panel 30, causing the side panels 11to define a perimeter. The side panel flap 31 is then ultrasonicallywelded to the first side panel 30 along weld joints 34, retaining theside panels 11 in place.

[0026] As shown in FIG. 4, in another embodiment, the shipping containeris formed from a two-piece blank which includes a first blank portion 40comprising a plurality of side panels 11 hingedly interconnected alongadjacent side edges 20. Side panel flaps 31 extend along opposite endsof the first blank portion 40, the flaps extending along an adjacentside edge 20. A second blank piece 41 is comprised of a first side panel30 and end panels 12,each end panel hingedly extending from opposite endedges 21. The container 10 is erected by positioning each flap31adjacent to opposite side edges of the first side panel 30, causing theside panels 11 to define a perimeter. Each flap 31 is thenultrasonically welded to the first side panel 30 along weld joints 34,retaining the side panels 11 in place.

[0027] As shown in FIG. 5, in another embodiment, the shipping containeris formed from a three-piece blank with a first blank portion 50comprising a plurality of side panels 11 hingedly interconnected to eachother along adjacent side edges 20. Second 51 and third 52 blankportions are comprised of individual end panels 12. A side panel flap31extends from a side edge 20 of a second side panel 53. The second 51and third 52 blank portions each define a plurality of end panel edges23, and includes flaps 24 which hingedly extend from the end panel edges23.

[0028] The container 10 is erected by positioning the flap 31 adjacentto the first side panel 54, causing the side panels 11 to define aperimeter. The flap 31 is ultrasonically welded to the first side panel54 along weld joints 34, retaining the side panels 11 in place. Thesecond 51 and third 52 blank portions are ultrasonically welded onto thefirst side panel 54 along its end edges 21. A flap 24 from each of thesecond and third 52 blank portions are ultrasonically welded onto thefirst side panel 54 along its respective weld joints 34.

[0029] While the embodiments disclosed in this application is typicallyultrasonically welded in place, other means for attaching components ofdisassembled blanks together, such as adhesives, staples, and fastenerscan also be readily used. Also, variations of the disclosed blanks mayalso be used in order to erect the subject shipping container 10.

[0030] As shown in FIG. 6, in one embodiment, the fastener 14 is a hookand loop fastener which includes a first fastener portion 22 having adistal end 61 secured along an internal surface 60 of the side panel 11.A second fastener portion 25 has a distal end 62 secured along aninterior surface 63 of the flap 24. The second fastener portion extendsthrough a first aperture 64 located on the flap 24 and a second aperture65 located on the side panel 11. A proximal end 66 of the first fastenerportion 22 and a proximal end 67 of the second fastener portion 25 isthen mated, securing the end panel 12 to the side panel 11.

[0031] This embodiment is preferred for attaching an end panel 11 whichwill form the bottom of the shipping container 10. The flap 24 and theside panel 11 provide excellent rectilinear support for the secondfastener portion, in the vertical direction, lessening the amount ofshear forces working to uncouple the proximal ends of the first andsecond fastener portions 66,67.

[0032] As shown in FIG. 7, in another embodiment, the fastener 14 is ahook and loop fastener which includes a first fastener portion 22 havinga distal end 71 secured along an internal surface 70 of the side panel11. The first fastener portion 22 extends through a first aperture 74located on the side panel 11. A second fastener portion 25 has a distalend 72 secured along an interior surface 73 of the flap 24. The secondfastener portion 25 extends through a second aperture 75 located on theflap 24. A proximal end 76 of the first fastener portion 22 and aproximal end 77 of the second fastener portion 25 is then mated,securing the end panel 12 to the side panel 11.

[0033] As shown in FIG. 8, a grommet 80 can also be used to secure theside panel 11 to the end panel 12. Overlaying apertures 81, 82 arerespectively created through the flap 24 and side panel 11. The grommet80 can include a shaft 84 which extends through the apertures 81, 82 anda head 83 which is diametrically greater than the aperture 81 throughthe flap 24. The head 83 serves to prevent a distal portion 85 of theshaft 84 from entering the aperture 81. A retaining clip 86 engages amiddle portion 87 of the shaft and prevents it from entering eitherapertures 81,82. The retaining clip 86 and the head 83 cooperate toretain the grommet within the apertures 81,82, and secures the end panel12 to the side panel 11.

[0034] The configuration of the subject shipping container 10 makes itparticularly suited for reusable use. The corrugated plastic materialand the ultrasonic welding provide a construction which is not easilydegraded by moisture or excessive handling. The releasable fasteners 14allow for relatively easy access to the interior of the shippingcontainer 10, while providing a secure seal. Furthermore, with itssides, top, and bottom, all comprised of a solid panel of material, theshipping container 10 provides improved protection against rupture, whencompared to the commonly used cardboard box configuration. The box isideally suited for use in situations wherein freight is reciprocallyshipped between entities.

[0035] As such, each shipping container 10 can also include a bar codelabel attached to an external surface, identifying each box. The barcode label can contain a UCC ID, a UCC reusable carton ID, and a serialnumber variable. The bar code label can be used to track the location ofthe box, or signify an owner to whom the box should be returned.

[0036] While particular embodiments of the present invention have beenshown and described, it will be appreciated by those skilled in the artthat changes and modifications may be made without departing from theinvention in its broader aspects. Therefore, the aim in the appendedclaims is to cover all such changes and modifications as fall within thetrue spirit and scope of the invention. The matter set forth in theforegoing description and accompanying drawings is offered by way ofillustration only and not as a limitation. The actual scope of theinvention is intended to be defined in the following claims when viewedin their proper perspective based on the prior art.

What is claimed is:
 1. A reusable shipping container comprising: aplurality of side panels; an end panel cooperating with the side panelsto define an interior space; and a fastener releasably and reusablysecuring the end panel to a side panel, each fastener extending throughboth the end panel and a side panel.
 2. The container of claim 1,wherein concentric apertures extend through an end panel and a sidepanel, and wherein the fastener includes a grommet releasably disposedwithin the apertures.
 3. The container of claim 1, wherein an end panelincludes at least one flap extending therefrom, and wherein a fasteneris secured to the flap.
 4. The container of claim 3, wherein thefastener is a hook and loop fastener.
 5. The container of claim 4,wherein the fastener includes a first portion with a distal end securedalong an internal surface of a side panel, the first portion extendingthrough the panel wall and a second portion having a distal end securedto an interior surface of the flap, the second portion extending throughthe flap, and wherein the first and second portion couples along anexternal surface of the flap.
 6. The container of claim 4, wherein thefastener includes a first portion with a distal end secured along aninternal surface of a side panel and a second portion having a distalend secured onto an interior surface of the flap, the second portionextending through the flap and a side panel to couple with the firstportion along an internal surface of a side panel.
 7. The container ofclaim 1, wherein each side panel defines a pair of side edges and a pairof end edges, and wherein the container is constructed of a one-pieceblank comprising a plurality of side panels interconnected alongadjacent side edges and wherein each end panel extends from an end edge.8. The container of claim 1, wherein each side panel defines a pair ofside edges and a pair of end edges, and wherein the container is madefrom a three-piece blank comprising a plurality of side panelsinterconnected along adjacent side edges and two separate end panels. 9.The container of claim 1, wherein each side panel defines a pair of sideedges and a pair of end edges, and wherein the container is made from atwo-piece blank comprising a plurality of side panels interconnectedalong adjacent side edges and a single side panel having end panelsextending from opposite end edges.
 10. The container of claim 1, whereinthe container is made of a corrugated plastic material.
 11. Thecontainer of claim 1 wherein the container is ultrasonically weldedtogether.
 12. The container of claim 1, and further comprising a barcode label attached along an external surface of a side panel, the barcode label containing a UCC ID, a UCC reusable carton ID and a serialnumber variable.
 13. A method of constructing a reusable shippingcontainer comprising: providing a blank comprising a pair of end panels,each with a flap extending therefrom, and a plurality of side panels;creating adjacent apertures in a side panel and a flap; securing afastener to a side panel and an end panel, the fastener extendingthrough the apertures;
 14. The method of claim 13, wherein the fasteneris a hook and loop fastener.
 15. The method of claim 13, wherein thestep of securing a fastener includes securing a distal end of a firstportion of the fastener along an internal surface of a side panel, thefirst portion extending through the aperture in the side panel, securinga distal end of a second portion of the fastener to an internal surfaceof the flap, and extending the second portion through the aperture inthe flap.
 16. The method of claim 13, wherein the step of securing afastener includes securing a first portion of the fastener to aninternal surface of a side panel, securing a distal end of a secondportion of the fastener along an internal surface of the flap, andextending the second portion through the apertures in the side and endpanels.
 17. The method of claim 13, wherein the apertures overlay eachother, and wherein the step of securing a fastener includes inserting agrommet through the apertures, and securing a clip on a portion of thegrommet intermediate to the side panel and flap.
 18. The method of claim13, wherein the blank is a one-piece blank comprising a plurality ofside panels interconnected along adjacent side edges, and each end panelextending from an end edge.
 19. The method of claim 13, wherein theblank is a two-piece blank comprising a plurality of side panelsinterconnected along and a single side panel having end panels extendingfrom opposite end edges.
 20. The method of claim 13, wherein the blankis a three-piece blank comprising a plurality of side panelsinterconnected along adjacent side edges and two separate end panels.21. The method of claim 13, and further comprising the additional stepof erecting the blank, and ultrasonically welding the erected blanktogether.
 22. A reusable shipping container comprising: a plurality ofside panels; a pair of end panels cooperating with the side panels todefine an interior space, the end panel defining an end panel edge andincluding a flap extending from an end panel edge; and a hook and loopfastener extending through a flap and side panel.
 23. The container ofclaim 22, wherein the container is made of a corrugated plasticmaterial.